Method and apparatus for arranging articles in a row



Nov. 18, 1969 R. E. MILLER ETA!- 3,479,024

METHOD AND APPARATUS FOR ARRANGING ARTICLES IN A ROW 8 Sheets-Sheet 1Filed Feb. 23, 1967 ZO- 47 ..I?

24: cuvrez cu-rrcz Z8 Z8 Z9 Z9 {cowsesea I couveesirz j .Zizzazzturzs47a POLAND 5. M4452 am: a A/AY/VE 506A? c. OLSON 205577 J e/Ara/z a; M;6% mtg Nov. 18, 1969 R. E. MILLER ETAL METHOD AND APPARATUS FORARRANGING ARTICLES IN A ROW Filed Feb. 23, 1967 8 Sheets-Sheet 2 liftPOLAND 5 MALE? 04705 0 WAY/V5 ROMETJP/ATFA Nov. 18, 1.969

Filed Feb.

R. E. MILLER ETAL 3,479,024

METHOD AND APPARATUS FOR ARRANGING ARTICLES IN A ROW 23, 1967 8Sheets-Sheet 3 n I 8 3 N L.

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Hi- I I I T. In a as azzztazzs? POLAND ISM/ALE? CLYOE D. WAYNE 50642 C0450 05537 4/. P4475! Nov. l8, 1969 R. E. MILLER ETAL METHOD ANDAPPARATUS FOR ARRANGING ARTICLES IN A ROW H re e :2 K m mummm n MA m w..5 i n c s .0 r 8 N52? AOA m wwm 059 Nov. 18, 1969 R. E. MILLER ETAL3,479,024

METHOD AND APPARATUS FOR ARRANGING ARTICLES IN A ROW Filed Feb. 25, 19678 Sheets-Sheet 6 ML- IS) 9 L l l .Ezzazztczzzs POZAND E. M/AZE? 62705 0.NA Y/VE 064? 6. 04 so/v 205.527 flMTZX Nov. 18, 1969 R. E. MILLER ET AL3,479,024 A METHOD AND APPARATUS FOR AHRANGING ARTICLES IN A ROW FiledFeb. 23, 1967 a Sheets-Sheet 7 mental-:5 POL/4N0 E M/LLEP CZ V05 a NAY/VE 6064,? c. 0; saw 206567 1 /A 75% United States Patent Office3,479,024. Patented Nov. 18, 1969 3,479,024 METHOD AND APPARATUS FORARRANGING ARTICLES IN A ROW Roland E. Miller, Orangeville, Clyde D.Wayne, Wilmette,

Edgar C. Olson, Waukegan, and Robert J. Piatek, Chicago, Ill., assignorsto National Dairy Products Corporation, Chicago, Ill., a corporation ofDelaware Filed Feb. 23, 1967, Ser. No. 621,095 Int. Cl. B6511 39/02; A0127/00; B65q 47/26 US. Cl. 270-58 24 Claims ABSTRACT OF THE DISCLOSUREMethod and apparatus for converging a given number of adjacent rowscfclosely spaced individual units into a lesser number of rows ofindividual units. In moving from an adjacent row to a converged row, theunits are accelerated to a velocity at least equal to the product of thegiven number of adjacent rows and the velocity of the individual unitsin the adjacent rows.

This invention relates generally to the packaging of presliced cheeseand, more particularly, to an improved method and apparatus forproducing an output line of individual cheese slices from a plurality ofadjacent cheese ribbons. Included in the invention is an improved methodand apparatus for converging a plurality of adjacent moving lines ofindividual cheese slices into a single output line of individual cheeseslices.

Presliced cheese is a readily saleable item due to the ease with whichit may be used in the preparation of food, both at home and on acommercial basis in restaurants, etc. In one type of automated systemfor making presliced cheese, a continuous sheet of Warm cheese is cooledby passing it over a large chilled cylindrical roll. As the sheet ofcheese leaves the chilled roll, it is slit to form continuous ribbons,each of which is then guided over suitable means and through a cuttingstation. As the ribbons move through the cutting station, they are cuttransversely of their length to form individual cheese slices which movein lines from the cutting station. The slices are then stacked andwrapped in moisture proof airtight packages, preferably by automatedmeans.

Naturally, it is costly to provide a separate automated wrappingoperation for each ribbon of cheese moving from the chill roll.Furthermore, it is possible to build automatic wrapping machines havinga capacity considerably greater than that which a single ribbon ofcheese moving from the cheese roll could provide. It is thereforedesirable that the individual cheese slices in a plurality of rowsformed by cutting a plurality of ribbons at a cutting station beconverged into a single moving composite line of individual cheeseslices.

Accordingly, it is an object of the invention to provide an improvedmethod and apparatus for producing a single row of individual cheeseslices from a plurality of adjacent cheese ribbons.

Another object of the invention is to provide an improved method andapparatus for converging a plurality of adjacent input lines ofindividual cheese slices into a single output line of individual cheeseslices.

A more general object of the invention is to provide improved cheesepackaging equipment.

A more particular object of the invention is to provide a convergingmethod and apparatus which minimizes the chance of slippage andmisalignment of the individual cheese slices being converged.

A further object of the invention is to provide a method and apparatusfor converging input lines of individual cheese slices into a singleoutput line and wherein overlapping of the cheese slices in the outputline is avoided.

A still further object of the invention is to provide convergingapparatus including means for selecting individual slices of cheese fromeach of a plurality of input lines in a predetermined order, andshifting the selected slices into successive alignment with each otherin the direction of movement thereof after accelerating such slices to agiven output velocity.

Various other objects of the invention, and the various advantages ofthe invention, will become apparent to those skilled in the art from thefollowing description taken in connection with the accompanying drawingswherein:

FIGURE 1 is a schematic diagram of a cheese packaging systemincorporating the invention;

FIGURE 2 is a perspective view of a portion of a chill roll and variouselements associated therewith used in the cheese packaging system ofFIGURE 1;

FIGURE 3 is a perspective view of an apparatus for cutting cheeseribbons used in the system of FIGURE 1;

FIGURE 4 is an enlarged sectional elevational view taken along the line4-4 of FIGURE 3;

FIGURE 5 is a top plan view showing a preferred pattern in which thecheese ribbons are cut by the apparatus of FIGURES 3 and 4;

FIGURE 6 is a top plan view of an apparatus forming a portion of thesystem of FIGURE 1;

FIGURE 7 is a fragmentary elevational view of the apparatus of FIGURE 6;

FIGURE 8 is an enlarged sectional end view taken along the line 88 ofFIGURE 7;

FIGURE 9 is an enlarged sectional end view taken along the line 99 ofFIGURE 7;

FIGURE 10 is a sectional plan view taken along the line 1010 of FIGURE7; and

FIGURE 11 through 14 are fragmentary elevational views, partially insection, illustrating successive steps in the operation of a portion ofthe apparatus of FIGURE 7, as viewed in the direction of the arrows14-14 of FIG- URE 10.

Very generally, the present invention is directed to a method andapparatus for transforming a plurality of ribbons 20 of cheese into alesser number of single file rows 21 of slices 22. In the illustratedembodiment, a continuous sheet of cheese 24 is slit to provide theribbons 20 which are advanced in side-by-side relation to a cutter 26.The cutter transforms each of the ribbons into a row of slices 22,thereby creating advancing side-by-side rows 28 of slices equal innumber to the original number of ribbons 20.

Individual slices are then selected from the multiple rows 28 in apredetermined order by a converger 29 and shifted into successivealignment with one another to form the desired lesser number of singlefile rows 21, these rows representing a combination of several of theribbons 20. The single file rows 21 are then delivered to a wrapping andpackaging apparatus 30. After being formed from the ribbons 20 and priorto achieving single file orientation in a composite row 21, theindividual slices 22 are accelerated to a given output velocity whichclosely approximates the product of the number of ribbons combined intoone row and the velocity of the ribbons.

In the illustrated embodiment, sixteen ribbons are combined or convergedto provide four single file rows of slices. The invention is notlimited, of course, to the transformation of any specific number ofribbons into a specific number of rows of slices and the particulararrangement selected is intended by way of illustration and notlimitation. The following discussion will be directed principally to theconvergence of eight ribbons into two single file rows, it beingunderstood that convergence of the remaining eight ribbons isaccomplished in an identical manner.

More specifically, and with reference to FIGURE 2, the sheet 24 ofcheese is produced through the use of a chill roll 36 onto which moltencheese is allowed to flow and cool. The sheet is removed from the chillroll by means of a scraper 37 and passed over a takeoff roll 38 where itis slit into a plurality of ribbons by a plurality of disc blades 41mounted on a suitable axle 39. After being cut, the individual ribbonsare passed over a guide roll 42 supported by a pair of arms 43, only oneof which is shown in FIGURE 2.

When a long chill roll is utilized and, thus, a large number of cheeseribbons are produced, it has been found convenient to employ at leasttwo automatic wrapping and packaging machines 30 and to divide theplurality of cheese ribbons into several groups, each group serving acorresponding one of the wrapping machines. Space considerations areoften such that the wrapping machines must be spaced laterally from eachother or from a position in direct alignment with the ribbons as theyleave the takeoff roll 38. In order to effect a spatial separation ofthe plurality of adjacent ribbons into a number of groups, the ribbonsare first collated to move them in a stack parallel with the' axis ofthe chill roll, and then are decollated in separate groups having thedesired spacing.

The collating operation is performed by a plurality of flanged collatorrollers 44 which are mounted for rotation about axes which are disposedto effect a 90 twist in each of the cheese ribbons. A decollatorconveyor 45 is disposed beneath the collator rollers 44 and the ribbonsare stacked one upon the other on this conveyor as they leave therollers and are moved in a direction parallel to the axes of the chillroll 36 and the takeoff roll 38.

Decollating of the stacked ribbons carried on the decollator conveyor 45may be accomplished in groups at desired positions along the path of thedecollator conveyor. In FIGURE 1, the sixteen ribbons formed aredecollated in groups of eight in order to feed two wrapping machines 30.FIGURE 2 is an enlarged view in perspective of the decollating of eightof the cheese ribbons. Decollating is accomplished by means of aplurality of flanged decollator rollers 46 which have axes parallel tothe axes of the collator rollers 44. The decollator rollers are disposedbeneath the moving stack of cheese ribbons just past the end of thedecollator conveyor 45. The ribbons are collated or stacked with eachsuccessive ribbon from right to left being supported on top of the nextpreceding ribbon; the stack of ribbons is decollated by diverting theribbons one at a time from the bottom of the stack. Thus, the firstribbon into the stack is the first out of the stack.

After passing over and around a given one of the decollator rolls 46,the lowermost cheese ribbon of the stack is directed downwardly, twistedapproximately 90, and guided around one of a plurality of horizontalflanged rollers 47 disposed in axial alignment with each other andsupported on a common shaft. After passing around a horizontal roller47, each of the cheese ribbons engages and is supported on a horizontalmoving decollator discharge conveyor 47a, only a portion of which isshown in the drawings (FIGURE 2). Thus, the cheese ribbons, as they moveon the discharge conveyor 47a, are disposed adjacent each other, arecoplanar, and are moving at the same generally constant speed. Thedischarge conveyor 47a delivers the ribbons to a cutter conveyor 48which in turn delivers cut slices 22 to the converger 29.

The cutter conveyor 48 (FIGURE 3) operates in a timed relationship withthe decollator discharge conveyor 47a, with the cutter 26, and with theconverger 29 so that the size of the slices and their removal from theconveyor may be accurately controlled. The conveyor 48 comprises aplurality of continuous timing "belts 49 provided with transverselyextending ribs 50 and grooves 51 on their under surface. Alternate belts49a are supported at their forward ends by splined pulleys 65 rotatablycar- .4 ried individually on the forward ends of brackets 67. Theremaining belts 49b are supported at their forward ends by splinedpulleys (not shown) carried on a shaft 69. The shaft 69 is rotatablymounted somewhat rearwardly of the rollers 65 so that the belts 49bterminate rearwardly of the termination of the belts 49a. The earliertermination of the belts 49b provides gaps 71 intermediate the forwardends of the belts 49a to facilitate the removal of the cheese slicesfrom the belts, as will become apparent shortly.

As will be noted from FIGURE 3, the ribbons 20, prior to being cut, aresupported so as to span the belts 49b, with an edge portion of eachribbon resting upon the edge portion of each of two belts 49a. Thisrelationship between the cheese and the belts is preserved after theribbons are cut. Thus, each of the slices 22 of the rows 28 also spans abelt 49b and is supported at its side edges by each of a pair of thebelts 49a. When the cheese slices reach the area where the belts 4% haveterminated, therefore, they span the gaps 71 for a brief duration,enabling them to be engaged from beneath by a portion of the converger29, as hereinafter described.

The ribbons 20 are moved by the cutter conveyor 48 to and past thecutter 26. The cutter 26 comprises (FIG. 3) a plurality of cylindricalsections 73 of substantially the same diameter keyed to a common driveshaft 75 journalled between two upright plates 77 attached to oppositewalls of a frame 79 of the machine. A gear 81 is drivingly secured onthe drive shaft 75 and is maintained in engagement with an idler gear 83mounted on an idler shaft 85. The idler shaft 85 is journalled in one ofthe plates 77 and carries a sprocket 87 connected by means of a chain 89to a sprocket 91 keyed to the spindle 93 of a gear box 94 suitablymounted, by means not illustrated, on the frame 79 of the machine. Amotor (not shown) is drivingly connected to the gear box 94. Preferably,the motor which drives the gear box 94 is also drivingly connected tothe conveyor 48, either through the gear box 94 or otherwise so that thesame motor drives both the conveyor 48 and the cutter 26, therebyinsuring synchronization between the two.

Each of the cylindrical sections 73 of the cutter 26 carries a pluralityof radially directed blades 95 spaced circumferentially about theperiphery thereof. As may be seen in FIGURE 4, the blades 95 are securedin their respective cylindrical sections 73 by means of mounting blocks97 which fit is suitable recessess 99 formed in the surface of thesections. The blocks 97 are secured to the section by means of bolts101. Each of the recesses 99 has an inclined wall therein and, upontightening of each of the bolts the block 97 associated therewith isforced against the blade. This wedges the blade against the wall of therecess opposite the inclined wall and holds the blade securely in placewithin the recess.

The. circumferential spacing of the outer ends of the blades 95 abouttheir respective cylindrical sections 73 corresponds to the desiredlength of the individual cheese silces. In the drawings, four blades areshown about the circumference of each section, but it is to beunderstood that variations are possible within the scope of theinvention. The tips of each of the blades 95 are sharpened and the motor63 drives the shaft 75 such that the tangential velocity of the tipsequals the linear velocity of the cheeseribbons 20* moving beneath. Atthe lower extent of their arcuate travel, the blades cooperate with thebelts 49 of the cutter conveyor 48 to cut the ribbons transversely toform the individual cheese slices. Because the blades are moving in thesame direction and at the same speed as the ribbons, there is nobunching or tearing of the cheese during the cutting process. In fact,the cheese ribbons are under a slight tension prior to being cut. Thistension is relaxed as the ribbons are cut, permitting a slight shrinkageof each individual slice and creating a slight gap 103 between eachslice and the immediately preceding and succeeding slices (FIG. 3).

Referring to FIGURE 5, it will be observed that the individual slices ofcheese leaving the cutter 26 are in staggered positions, that is, notdirectly abreast of each other, for reasons subsequently explained inconnection with the operation of the converger 29. More specifically,

the ribbons are cut so that each transverse cut of any one ribbon isspaced longitudinally from rather than aligned with the transverse cutsof an adjacent ribbon. This longitudinal spacing is approximately equalto the quotient of the distance between cuts in any one strip divided bythe given number of strips. The slices are aligned in pairs spacedtransversely of the direction of movement, each pair being comprised ofone slice from one of the four lines toward the left, and of one slicefrom one of the four lines to the right when considering the slicesproduced from eight ribbons. In this manner, two slices are presentedfor pickup by the converger at the same time. Thus, the slices shown inFIGURE 5 and designated 221: through 22h are typical of those formed bya fraction of a revolution of the cutter shaft 75. It will be seen thatslices 22a and 22g are in transverse alignment, as are slices 22b and 2222c and 22e, and slice 22d and a slice 22h of a succeeding set. Thisspecific arrangement has been found to be preferable in that it avoidsinterference between the slices as they are picked up by the converger.

The slices 22 are delivered by the cutter conveyor 48 to the converger29, the basic function of which is to converge or combine each set offour adjacent horizontal input lines of cheese slices 28 into a singleoutput line 21 of individual cheese slices. In the illustratedapparatus, the converger combines two groups of four input lines intotwo single output lines, one for each group.

The particular structure of the converger is illustrated in FIGURES 6through 10. Some elements in these figures are broken away or left outfor clarity.

The converger includes a plurality of cheese-carrying elements orpickers 105, each of which is adapted to carry an individual cheeseslice 22. In FIGURES 7 and 8, the details of the pickers includes a pairof projecting prongs 107 having flattened tips or shelves 109 forcontacting the underside of the cheese slice which it supports. Thewidth of the pickers at the prongs is such as will enable the prongs tofit into the gaps 71 intermediate the belts 49a and engage the cheeseslices from beneath. The prongs extend from a tubular body 111 ofrectangular external and internal cross section, and may be welded tothe body 111 or may be formed integral therewith in a casting.Plastichas been found to be a suitable material from which the pickerscan be fabricated.

The pickers 105 are supported on a plurality of cross bars 113, each ofwhich carries two pickers. The cross bars 113 are of rectangular crosssection and extend through the tubular bodies 111 of the pickers. Thetubular bodies are free to slide longitudinally along the cross bars 113but, because of the rectangular mating cross sections of the pickers andcross bars, the pickers will turn when the cross bars are rotated.

Each of the cross bars carries a pivot element 115 and 117,respectively, at its opposite ends. Basically, the pivot elementscmprise a cylindrical body with a pair of spaced flanges on each endthereof. The pivot elements 115 are all rotatably mounted intermediatethe links of a traveling conveyor chain 119. Similarly, the pivotelements 117 are all rotatably mounted intermediate the links of atraveling conveyor chain 121. (In FIGURES 610, parts of the chains 119and 121 are broken away to show sprockets 123 and 125, discussed below,by which they are supported.) The chains are of identical size and thespacing of the pivot elements 115 and 117 therealong is such that thecross bars extend between the chains perpendicularly thereof and areevenly spaced from each other. The cross bars move with the chains and,because of the pivot elements 115 and 117, are free to rotate withrespect thereto.

In order to guide and drive the two chains 119 and 121 simultaneously,four sprockets 123, 125, 127 and 129 are provided, each of which haveteeth which drivingly engage one of the chains. Thus, the two sprockets123 and 127 engage the chain 119, whereas the two sprockets 125 and 129engage the chain 117. The sprockets 123 and 125 are mounted on a driveshaft 131 near the opposite ends thereof, and the sprockets 127 and 129are mounted on an idler shaft 133 near its opposite ends. The shafts 131and 133 are suitably journalled at their ends in the frame 79. Drivingtorque is transmitted to the drive shaft 131 through a drive sprocket orgear 135 keyed to the shaft near the sprocket 123. The drive sprocket orgear 135 is drivingly connected to an output shaft of a gear box (notshown) driven by the motor which also powers the cutter 26 and cutterconveyor 48. Upon rotation of the drive shaft 131, the sprockets 123through 129 and the conveyor chains 119 and 121 are simultaneouslydriven so that the cross bars 113 move parallel with each other and withthe chains, forming a continuous conveyor for carrying the pickers 105.Two chains tracks 137 (FIGS. 8 and 9) are supported, by meanssubsequently explained, between the sprockets 123-129 and serve tosupport and guide the upper runs of the chains, as they pass between thesprockets, by engaging the undersides of the chains.

The position of the pickers 105 is regulated both as to the orientationof the shelves 109 of the prongs 107 With respect to the horizontal andas to the position of the pickers on the cross bars 113 upon which theyare slidably mounted. Movement of the pickers along the cross bars 113initially places them in position to engage from beneath the individualslices of cheese delivered by the cutter conveyor 48 and subsequentlycauses them to converge the several input lines 28 of cheese slices intoa pair of output lines 21. Control over the orientation of the pickerscauses the shelves 109 to lie in a horizontal plane from immediatelyprior to the pickup of the cheese slice until after the slice has beenremoved from the picker thereby minimizing shifting movement of theslice on the shelf.

Referring first to the orientation of the pickers, the

pickup of the cheese slices by the pickers occurs while the pickers aremoving in an arcuate ascending path, i.e., at the point of travel of thepickers at which the cross bars carrying them are passing around thesprockets 127 and 129. Normally during such movement, the flatsliceengaging surface 109 of the prongs 107 would be inclined relativeto the horizontal. However, such a disposition of the surface would notbe conducive to an orderly pickup of the slices. Accordingly, thepickers are guided in their movement so that the fiat upper surface ofthe prongs remains generally horizontal as the picker moves upwardlyfrom beneath the slice and engages the slice and until the slice isremoved from the surface 109.

I In this regard, a cam track or groove 139 in the shape of a closedloop (FIG. 7) is provided in a vertical plate 141 which is secured toone wall of the frame 79 of the machine. Each of the pivot elements 117of the cross arms 113 has an arm 143 keyed thereto on the opposite sideof the chain 119 from the pickers. The arms extend inwardly toward thecamming groove 139 and terminate adjacent thereto. Each of the armscarries a cam follower roller 145 which is received in the groove andmoves therein as the chain 117 moves about the sprockets 125 and 129.The arms 143, being keyed to their respective pivot elements 117,control the rotative orientation of the cross bars 113 according to thecontour or configuration of the groove 139. Due to the mutualrectangular cross sections of the pickers 105 and the cross bars 113,the position of the arms 143 will also regulate the rotative orientationof the prongs 107 and shelves 109 on the pickers with respect to thehorizontal.

The effect of the camming groove 139 on the position of the pickers 105and, more particularly, on the shelves 109 thereon may be seen best inFIGURE 7. As viewed in that figure, the movement of the pickers 105 isclock- Wise, approaching the slices 22 in an arcuate path fromunderneath, The camming groove 139 is shaped such that the position ofthe shelves 109 on the pickers will be as shown in phantom at theleft-hand edge of the figure. Just prior to and following passage of thepickers 105 between the belts 49a of the cutter conveyor 48, the shelves109 are maintained in a horizontal position. Thus, they evenly engagethe underside of the cheese slices and lift them from the conveyor. Theshelves are maintained in a horizontal disposition until they havedeposited the cheese slices on an output conveyor 147 as will besubsequently described.

In order for the converger to carry away all of the cheese slicesdelivered to it from the plurality of input lines which it services, thepickers are moved at a velocity which is several times greater than theinput velocity of the ribbons 20. The order of magnitude by which theoutput velocity is greater than this input velocity preferablycorresponds at least to the number of ribbons being converged into asingle row. In the illustrated apparatus, four input lines are beingconverged into a single output line and, consequently, the pickers 105travel at a speed which is about four times that of the ribbons 20. Bymaking the output velocity at least this magnitude, the slices in theoutput line will not overlap but will be spaced to the same degree aswhen they are cut. They are therefore easily handled by the wrappingmachine 30. This assumes, of course, that approximately the same spacingis desired between the slices in the output row as in the input rows. Itmay be desirable to effect a greater spacing between the slices in theoutput row to facilitate wrapping, in which case the output velocitywould be an even greater multiple of the input velocity. It would bepossible, of course, to accelerate the slices in two stages through theuse of an intermediate conveyor so that the acceleration imparted by thepicker would be less than the product of the number of ribbons and theirinput velocity, although the total acceleration would remain the same.In the illustrated embodiment, a unit is removed from each row in apredetermined repeating sequence, each selection being made at a timeinterval which approximates the quotient of the time elapsing while oneunit travels a distance equal to its own length divided by the number ofrows of units being condensed into a single row.

Transfer of cheese slices between the cutter conveyor 48 and theconverger pickers 105 could conceivably cause slippage or disorientationof the cheese slices with respect to each other and their direction ofmovement since the pickers are moving at a much greater speed than theconveyor, and since the change in speed of the cheese slice occurs overa relatively short interval of time, necessitating a rapid accelerationof the slice. Where the cheese slices are subsequently to pass into aWrapping machine, this misalignment could prevent proper wrapping of thecheese slices. Furthermore, such misalignment may be severe enough thatthe cheese slices could topple into the machinery and become destroyed.

The converger 29 of the present invention avoids this problem byeffecting engagement between the cheese slice and the picker at thatpoint in the travel of the picker in which it has a horizontal velocitycomponent which is equal to the speed of the cutter conveyor and aresultant speed equal to the desired ultimate speed of the slice. Theacceleration of the slice is therefore essentially entirely vertical,causing the slice to bear down upon the shelf 109 of the picker butcreating no horizontal forces which could cause the slice to shift onthe shelf.

In determining the precise location of this ideal point of transfer, itwill be recalled that the ultimate velocity of the cheese slices is atleast equal to the product of the velocity of the cheese ribbons and thenumber of ribbons. This ultimate velocity has a horizontal componentequal to the velocity of the input conveyors, i.e., the velocity of theribbons, when the direction of the ultimate or resultant velocity is atan angle to the horizontal whose cosine is equal to the ratio of thevelocity of the ribbons to the desired ultimate velocity. Since theresultant velocity is a tangential velocity as the pickers move in acurved path at the entry end of the converger, the desired point is thatpoint at which a tangent to this path is at the abovementioned angle tothe horizontal. The path, of course, is the path of the cross bars 113on which the pickers are supported. If a slightly greater ultimatevelocity is de sired, a slightly greater angle will be used.

EXAMPLE Four ribbons are delivered to an input conveyor which is movingat a velocity of 500 in./ min. The ribbons are cut into slices whichmove at the same velocity. The slices are converged into a single row ofslices moving at a velocity of 2000 in./min. The ratio of the initialvelocity of the ribbons (500 in./min.) to the ultimate velocity of theslices (2000 in./min.) is 0.250, which is the cosine of 755. The pickuppoint, therefore, lies approximately on a line drawn through the pointwhere a tangent to the arcuate path of the cross bars is at an angle of75.5 to the horizontal. The line drawn through this point is at thecomplementary angle of 14.5 to the horizontal.

Thus, at the instant each cheese slice is picked olf the cutter conveyor48 by the pickers 105, the horizontal velocity of the conveyor and thehorizontal velocity of the shelves 109 of the pickers will be the same.As the pickers complete their arcuate path and begin moving onlyhorizontally, the horizontal velocity of the pickers and, hence, thecheese slices carried thereby will have accelerated from the velocity ofthe cutter conveyor to the velocity of the output conveyor 147.

As the pickers move through their arcuate paths to engage and lift thecheese slices from the input conveyors, they are maintained in alignmentwith the gaps 71 between the conveyor belts 49a such that the prongs 107on the pickers will pass into the gaps. This alignment is accomplishedby a plurality of guides 149 (see FIGURE 8) which are mounted on acylindrical drum 151 coaxial with the sprockets 127 and 129. The drum151 is mounted on the shaft 133 and is spaced from the sprockets 127 and129 by spacer bushings 153. Each of the guides 149 includes a pair ofspaced apart rectangular sides which extend radially outwardly from aweb 156 secured to the drum 151. The guides are positioned in apredetermined pattern about the periphery of the drum in accordance withthe order and position of the respective pickers 105 as they arereturned to the input conveyor end of the converger, as will beexplained subsequently.

In order to effect engagement between the pickers 105 and the guides149, each picker is provided with a forwardly extending appendage 158(FIGS. 11-14) on which is mounted a cam follower Wheel 157. The spacingof the rectangular sides 155' on the guides 149 is such as toaccommodate the cam follower wheel 157 of the pickers. The underside ofeach picker is provided in addition with a downwardly extendingappendage 158 which carries a pair of spaced cam follower wheels 159mounted for rotation about axes normal to the axis of the cross bar 113on which the picker is carried. As the drum 151 rotates, at the sameangular velocity as the sprockets 127 and 129, the guides 149 move withthe pickers 105 as the links of the chains 119 and 121 to which they arecoupled are passed around the sprockets. The walls or sides 155 preventmovement of the pickers 105 along the cross bars 113 upon which they areslidably mounted, and thereby proper alignment of the pickers withrespect to the gaps 71 between the conveyor belts 49a is maintained. Theprecise manner in which each of the pickers is aligned with the properone of the guides 149 on drum 151 as the pickers return from the outputconveyor end of the converger will be explained in detail subsequently.

The converger includes a system of cams for guiding the pickers 105 fromtheir diverged positions at the cutter conveyor 48 into single filealignment in the direction of movement. This enables the pickers todeposit the cheese slices on the output conveyor 147 in a single line.The convergence cam system includes a pair of cross bars 161 (FIGS. 7and 8) which are mounted to extend between opposite walls of the machineframe 79 by flanges 163. A pair of mounting brackets 165 are attached toeach of the two bars 161 toward the ends thereof and support eightconvergence cam tracks 169, each of which consists of a wide metal stripfastened on its edge to the top surface of the brackets 165. The camtracks 169 are received intermediate the cam wheels 159 of the pickersand are shaped to displace the pickers 105 along the cross bars 113 towhich they are slidably fastened, and to thereby cause the pickers toconverge into a single line moving toward the output conveyor. As may beseen in both FIGURES 6 and 7, the cam tracks overhang the brackets 165toward the drum 151 and approach the periphery of the drum closely.

As the guides 149 on the drum 151 drop away from the pickers 105 at thebeginning of the horizontal movement of the pickers between the two endsof the converger, one of the cam wheels 159 on each of the pickersengages the side of one of the cam tracks 169. The cam tracks at thisend are spread out across the width of the converger in order to receivepickers from each of the guides 149 on the drum. As the chains 119 and121 continue to move the pickers toward the output conveyor, theconvergence cam tracks guide each of the pickers into alignment with oneof two output lines. The height of the cam tracks varies, the two middletracks in each group of four being higher than the outer two. This is toallow for clearance of the other of the cam wheels 159, the latter beingmounted at varying levels for selection of the pickers as they arediverged in their return path, as explained below.

Because of the staggered cut of the cheese slices, as explainedpreviously in connection with the cutter 26, and because of thepositioning of the pickers and the horizontal acceleration thereof, theapparatus illustrated converges two groups of four input lines each ofindividual cheese slices into two output lines, with each of the twopickers on one of the cross bars 113 serving a different output line.The cam wheels 159 on the pickers 105 are spaced from each other suchthat, at the sharpest angle of the convergence cam track, bo h rollerswill contact the cam track and roll against the surface thereof toprevent binding.

After moving from the input end of the converger 29 at which the cheeseslices are picked up by the pickers 105, the pickers move toward theoutput end of the converger where the individual slices 22, which arenow moving in two output lines 21, each of which represents the totalslices in four input lines 28, are deposited upon the output conveyor147. The output conveyor (FIGS. 6 and 7), like the cutter conveyor 48,is constructed so as to provide spaced conveyor sections so as to definegaps 148 which permit the pickers to pass through the gaps whiledepositing the slices on the conveyor, as hereinafter described. Theupper level of the output conveyors is very slightly below that of thehighest level of the shelves 109 of the pickers 105. Thus, as thepickers pass through the gaps 148 of the output conveyors 147, thecheese slice carried on each picker moves over the output conveyor,straddling the gap. As the chains 119 and 121 pass around the sprockets123 and 125, the pickers drop through the gap so that each cheese slicebecomes deposited on and entirely supported by the conveyor. The outputconveyor is caused to travel at the speed of the pickers and there is nochange in the velocity of the slices.

In order to maintain the position of the pickers 105 so that they remainwithin the gaps of the output conveyors 147 after the convergence camtracks 169 terminate, and so that they arrive at a diverging station ina predetermined position, a pair of flanged wheels 173 and 175 areprovided and are mounted on the drive shaft 131 (FIGS. 6, 7 and 9). Theflanged wheels rotate with the shaft 131 and, hence, with the sprockets123 and 125. Each of the wheels is in alignment with one of the outputlines 21, each Wheel servicing a converged group of four input lines 28.As the pickers approach the periphery of the wheels 173 and 175, thewheel flanges pass on either side of one of the rollers 157 on theundersides of the picker. The particular roller which is guided variesin suc ceeding pairs of pickers, as explained below, and by guid ing theroller therein between the flanges of the wheel, the picker 105 isprecisely positioned on the cross bar 113 upon which it is mounted.

Provision is made for maintaining alignment of the pickers with theflanged wheels after the cam tracks terminate. This is accomplished byguide rails 177 supported on brackets 179 which, in turn, are bolted tofurther brackets 181. The brackets 181 extend from the previouslyreferred to brackets which support the cam tracks 169, and may be weldedto such brackets. As may be seen in FIGURE 9, the rails are positionedto contact opposite ends of the body 111 of each picker 105 to preventit from moving along the cross bar 113 on which it is secured.

After depositing the cheese slices on the output conveyors, the pickersare returned to the input conveyors and to their diverged position inorder to once again pick up the incoming lines of cheese slices. Thecams for accomplishing the divergence of the pickers are supported on acam support plate 183, which is mounted to a pair of cross bars 185 bymeans of four brackets 187, two on each cross bar. Each of the crossbars 185 is mounted to the frame 79 by flanges 189 and extends betweenthe two walls of the frame at a location betlween the sprockets 123-129driving the chains 119 and 121. The lower portions of the chains betweenthe sprockets are kept from sagging by two chain tracks 191 supported onbrackets 193 attached to the frame 79.

Each successive picker, as it leaves the area of guidance by one of thewheels 173 and 175, is diverged to a different position with respect tothe input conveyors. The return cam guidance system provided is designedto select the proper picker for each of several divergence cam tracks195. Referring particularly to FIGURES 11 through 14, it may be seen howthe apparatus selects each of four immediately successive pickers toguide same along a different one of the cam tracks as the pickers leavethe guide wheel 173 and begin their return movement in the direction ofthe cutter conveyor 48. By comparing the various figures, it will beseen that the two appendages 158 on the pickers 105 vary in theirlength. Thus, as the picker in FIGURE 11 leaves the wheel 173, the wheel159 furthest to the right will engage the cam track 195d and be divertedalong this cam track. As will be noted in FIGURE 10, the forward end ofthe track 1950, i.e., the end nearest the output end of the converger,is located far enough rearwardly of the forward end of the cam track195d to avoid interference between the wheel furthest to the left (FIG.11) and the track 195a.

The picker which is immediately behind the one illustrated in FIGURE 11,shown in FIGURE 12, has a sufliciently short right-hand appendage 158 topermit the right hand wheel 159 thereon to ass under the cam track 195d.Thus, divergence of the picker of FIGURE 12 will not occur until theright-hand one of the wheels 159 strikes the surface of the cam track195c. The cam track 195c projects a sufficient distance from the supportplate 183to engage the wheel 159 furthest to the left.

In so far as the picker shown in FIGURE 13 is concerned, the appendage158 is on the left side of the body 111. Furthermore, the left-handportion of the appendage is sufliciently short to permit the wheel 159thereon to clear the cam track 195a. As a result, divergence of thepicker of FIGURE 13 will not occur until the right hand wheel 159strikes the cam track 19511, the latter projecting a suflicient distancefrom the support plate 183. Finally, in the picker shown in FIGURE 14,the wheels 159 are of equal elevation and the left-hand wheel 159 isguided by the cam track 195a. As a result, when the l 1 picker of FIGURE14 leaves the guide wheel 173, the wheel 159 on the left-hand side willstrike the surface of the cam track 195a to be guided thereby. Locationof the forward end of the track 195b rearwardly of the forward end ofthe track 195a prevents interference between the track 195k and theright-hand roller 159.

Returning now to FIGURE 10, it will be seen that the 1 planconfiguration of the cam tracks 195 is such that the pickers will beguided to four positions spaced along one-half of the axial length ofthe drum 151. Upon returning to the drum in these positions, the guides149, which are suitably positioned on the drum, will guide the pickersbetween the appropriate belts of the cutter conveyor 48. The cam tracks195e through 195g are of a similar configuration to the four cam tracksjust described, and the pickers being guided by the wheel 175 will bereturned to these cam tracks in the same manner as just described.

Referring now more specifically to the construction of the outputconveyor 147, as illustrated in FIGURES 6 and 7, it will be seen thatthe conveyor comprises a frame which includes two pair of horizontallyspaced vertically arranged side plates 197. Each plate carries a studshaft 199 adjacent its rearward end, with each stud shaft projectinginwardly toward the opposite plate of the pair. Each stud shaft 199 hasrotatably mounted on it a sprocket 201. In addition, a shaft (not shown)extends between each pair of plates forwardly of the shafts 199 andcarries apair of sprockets (not shown), each of which is aligned with asprocket of a stud shaft 199. The sprockets carry a chain to which areattached bars 203 which define a flat surface for receiving the cheeseslices 28. The rearward shaft also carries a drive sprocket (not shown)suitably connected to a power source for driving of the shaft andassociated chain.

Thus, between each pair of plates 197 two bar conveyors 205 areprovided, these conveyors being horizontally spaced a sufficientdistance to permit passage of the pickers therebetween. As the pickermoves downwardly through the gap between the conveyors 205, the lateraledge portions of the slices which overhang the lateral edges of thepickers, engage the bar conveyor and are supported thereby.

In order that the central portion of the slice deposited by the pickersmay also be supported, a plate 197 of each pair carries a bracket'207having mounted on it a rearwardly extending arm which carries at itsrearward end a rotatably mounted pulley 209. A similar pulley 211 ismounted rearwardly of the pulley 209 on a shaft 213 which carries asprocket 215 for imparting rotation to the shaft through a suitablepower source. The pulleys 209 and 211 carry an O-ring belt 217 of verynarrow diameter which, together with the arm of the bracket 207, isnarrow enough to pass between the prongs 107 of the pickers 105 as thepickers in turn pass between the conveyors 205. Thus, the centralportion of the slice is supported by the O-ring belt 217.

To review the operation of the apparatus from the beginning, and inconnection with the formation of a single output line 21 of individualcheese slices 22, the cheese leavng the chill roll 36 is cut intoribbons by the blades 41. The ribbons of cheese 20 are collated into astack by the collator rollers 44. Upon reaching the decollator rollers46, the ribbons are peeled off and carried on the flat cutter conveyor48 in adjacent horizontal relationship. The cutter 26 cuts the ribbonstransversely to form a plurality of slices of cheese. These cheeseslices are carried in lines, referred to herein as input lines 28, bythe cutter conveyor to the converger 29.

The cheese slices of four of the input lines are picked up by theconverger 29 and are converged into a single output line which is movingat a velocity which is four times that of the ribbons 20. This isaccomplished by a plurality of pickers 105 which pick up cheese sliceshaving a horizontal velocity which is the same as the velocity of thecutter conveyor 48, accelerate them to the velocity of the outputconveyors 147, and move them into a single line. The converger thentransfers the cheese slices to the output conveyor 147 which carries thecheese on to a wrapping and packaging machine 30. Thus, the four ribbons20 are formed into four input lines 28 of individual cheese slices 22,and then are converged into a single output line 21 of individual cheeseslices, all automatically.

It may therefore be seen that the invention provides an improved methodand apparatus for producing an output line of individual cheese slicesfrom a plurality of adjacent cheese ribbons. The invention also providesan improved method and apparatus for converging a plurality of adjacentmoving lines of individual cheese slices into a single output line ofindividual cheese slices. The spacing between the cheese slices in theoutput line is such as to prevent overlap and the quantity of cheeseslices being conveyed by an output line is the same as the totalquantity of the converged input lines.

Various other embodiments and modifications thereof in addition to thoseshown and described herein will be apparent to those skilled in the artfrom the foregoing description. For example, it should be clear that theinvention is not limited to the handling of cheese and may be equallyefl ective in the conversion of strips of various other materials into asingle file row of units. Such other embodiments and modificationsthereof are intended to fall within the scope of the appended claims.

What is claimed is:

1. A method of producing a single file row of individual units from agiven number of adjacent strips moving in a given direction at agenerally constant velocity, which method comprises cutting each of themoving strips transversely at a first station to form a given number ofadvancing adjacent rows of individual units, longitudinally moving theadjacent rows from the first station to a second station, selectingunits from each of the rows in a predetermined order at the secondstation and shifting said selected units into successive longitudinalalignment with each other, and accelerating said units after the cuttingof the strips and before the aligning of the individual units to avelocity at least equal to the product of the given number of strips andthe velocity of the strips.

2. A method in accordance with claim 1 wherein the transverse cuts inthe advancing strips are made so that each cut in each strip is spacedlongitudinally relative to the cuts in the other strips, thereby causingthe unit-s to arrive at the second station one at a time atpredetermined time intervals, and wherein the units are selected in theorder of their arrival at the second station.

3. A method in accordance with claim 2 wherein the strips are cut sothat the leading edges of adjacent strips in adjacent rows are initiallyseparated longitudinally by a distance approximating the quotient of thedistance between cuts in any one strip divided by said given number ofstrips.

4. A method of converging a given number of adjacent rows of closelyspaced individual units into a single row of individual units,comprising selecting individual units from each of the rows in apredetermined order at a first station, accelerating said selected unitsto a velocity in the direction of movement of the units at least equalto the product of the given number of rows and the velocity of theindividual units in the rows, and shifting said selected units intosuccessive alignment with each other while maintaining the velocity towhich they were accelerated.

5. A method in accordance with claim 1 wherein the predetermined orderof selection is one unit from each line in repeating sequence, andwherein selection of the units is made at a time interval whichapproximates the quotient of the time elapsing while one unit travels adistance equal to its own length divided by said given number of rows ofunits.

6. A method in accordance with claim 1 wherein the units are sliceswhich lie in substantially horizontal planes during their movement.

7. A method in accordance with claim 1 wherein the individual units aremoved in an arcuate vertically ascendin'g path upon selection at thefirst station so that the acceleration of the units is initiallyessentially entirely vertical but ultimately horizontal.

8. A method in accordance with claim 1 wherein the individual units areselected by elements moving through an arcuate vertically ascendingpath, and wherein the point of selection along the path is that point atwhich a line tangent to the path forms an angle with respect to thehorizontal whose cosine is equal to the ratio of the forward velocity ofthe units to the resultant of the forward and vertical velocities of theelement.

9. An apparatus for producing a single file row of individual units froma given number'of adjacent strips, which apparatus comprises means formoving the strips longitudinally through a first station to a secondstation at a generally constant velocity, cutter means for cutting eachof the moving strips transversely at the first station to form a givennumber of advancing adjacent rows of individual units, means forselecting individual units from each of the rows in a predeterminedorder at the second station and for shifting the selected units intosuccessive alignment with each other in the direction of movementthereof, and means for accelerating the units after the cutting of thestrips and before the aligning of the individual units to a velocityequal to the product of the given number of strips and the velocity ofthe strips.

10. An apparatus for converging a given number of adjacent rows ofclosely spaced individual units into a single file row of individualunits, said apparatus comprising means for selecting individual unitsfrom each of the rows in a predetermined order at a first station andfor accelerating said selected units to a velocity in the direction ofmovement of the units while moving such selected units to a secondstation, the velocity of the units after acceleration being at leastequal to the product of the given number of rows and the initialvelocity of the strips, and means for shifting the selected units intosuccessive alignment with each other in the direction of movementthereof.

11. An apparatus in accordance with claim 9 wherein said selecting andaccelerating means comprises a conveyor having a plurality of elementsthereon adapted to engage the units, said conveyor being constructed tomove said elements thereon through an arcuate path such that a tangentthereto at the point of selection is approximately at an angle withrespect to the direction of movement of the input lines whose cosine isequal to the ratio of the forward velocity of the units to the resultantof the forward and vertical velocities of each of the elements.

12. Apparatus in accordance with claim 9 wherein said selecting andaccelerating means comprises a conveyor having a plurality of elementsthereon adapted to engage the units, said elements being carried by saidconveyor at longitudinally spaced intervals relative to each other in amanner corresponding to the predetermined order of selection.

13. Apparatus in accordance with claim 12 wherein said elements aremovable on said conveyor transversely of the direction of theiracceleration, and wherein said shifting means comprise a plurality ofcams for moving said elements into successive alignment with each otherin the direction of movement of said conveyor.

14. An apparatus for converging a plurality of adjacent coplanar movingrows of individual units into a single moving row of individual units,said apparatus comprising an input conveyor for carrying a plurality ofadjacent rows of individual units, an output conveyor adapted to movethe single row of individual units in the same direction as said inputconveyor at a speed which is substantially greater than the speed ofsaid input conveyor, and means intermediate said input and outputconveyors for engaging and carrying the units from said input conveyorto said output conveyor in the same direction as the movement of saidinput and output conveyors while accelerating the units to a velocity atleast equal to the product of the given number of rows of individualunits on the input conveyor and the velocity of the individual units onthe said input conveyor, said means including a converger conveyorhaving a plurality of transversely movable elements thereon for engagingand carrying the units and cam means for moving said elements frompositions aligned with and adjacent to respective moving rows of unitson said input conveyor to a position aligned with and adjacent to saidsingle moving line of units on said output conveyor.

15. Apparatus in accordance with claim 14, wherein the units aredelivered directly to said output conveyor by said converger conveyor,wherein means are provided for moving said converger conveyor elementsat the speed of said output conveyor in the direction of movementthereof at the time the units are delivered to said output conveyor,wherein said converger conveyor is provided with a plurality of barsmoving therewith and extending transversely of the direction of movementof said output conveyor, wherein said elements are slidably supported onsaid bars, and wherein said cam means are adapted to engage and slidesaid elements along said bars.

16. An apparatus in accordance with claim 14, wherein said inputconveyor comprises a plurality of spaced input conveyor sections adaptedto support the units with such units straddling the spaces between saidspaced sections, and wherein said elements include portions adapted topass between said sections and engage the units from beneath.

17. An apparatus in accordance with claim 9 wherein said selecting meanscomprises a plurality of elements carried by a moving conveyor along anendless path, each of said elements defining a supporting surfaceadapted to engage the lower surface of a unit, said conveyor beingadapted to move said elements through an arcuate path in which saidsupporting surface is brought into engagement with a unit from beneath,and wherein means are provided for maintaining said supporting surfacegenerally horizontal from immediately prior to its engagement of theunit until after the removal of the unit therefrom, including during itsmovement along the latter portion of said arcuate path.

18. Apparatus in accordance with claim 17, wherein said means formaintaining said supporting surfaces of said elements generallyhorizontal comprises bars for supporting said elements and to which saidelements are keyed, a cam track loop lying in a plane which issubstantially perpendicular to the plane of the arcuate path of saidelements, and a plurality of arms each rigidly secured to one of saidbars for turning same, said arms each having a cam follower securedthereto and adapted to follow said cam track loop.

19. An apparatus in accordance with claim 9, wherein said cuttercomprises an element rotatable about a horizontal axis and cutter bladesextending from said element generally radially of said axis, an equalnumber of cutter blades being provided for each of said strips, each ofsaid blades being aligned with one of said strips, each of said cutterblades being spaced circumferentially from an immediately adjacentcutter blade by an angle equal to the quotient of 360 divided by thetotal number of blades.

20. An apparatus in accordance with claim 13, wherein sets of saidelements are provided, each set including one element for each of saidstrips, and wherein a cam is provided for each element to guide saidelement into alignment with a predetermined row of individual units 15and then shift it into alignment with each of the other elements to forma single row.

21. An apparatus in accordance with claim 19, wherein means are providedto automatically associate each element with a preselected cam track foreach cycle of operation.

22. An apparatus in accordance with claim 20, Wherein said meanscomprises a cam follower on each of said elements, said cam followersbeing arranged at different locations on each of said elements, each ofsaid locations corresponding to the location of one of said cam tracks.

23. An apparatus in accordance with claim 12 wherein said elementstravel in a closed path from a receiving station, past a deliverystation, and back to the receiving station, wherein each of saidelements includes a bifurcated arm providing prongs arranged inside-by-side order in a direction transverse to the unit flow, andwherein a takeoff conveyor is provided to receive units from saidelements, said take 01f conveyor including a narrow section adapted topass between said arm segments and engage References Cited UNITED STATESPATENTS 4/1963 Morton et a1. l9832 X 9/1966 Disbrow et a1 27058 EUGENER. CAPOZIO, Primary Examiner PAUL V. WILLIAMS, Assistant Examiner U.S.Cl. X.R.

